Hey guys,
   I just picked up a 86 sammy a few weeks back and I am not preparing to start the process of making it a worthy off road vehicle. I've cleared out space in my garage to work in it but I'm not sure where to start.  So far the sammy is stock except for a home brew SPOA lift with 31" tires. I will primarily be driving it off road but I want to be able to use it as a spare car so it needs to be street legal as well. My first thought was to go with a 4.16 crawler transfer case from RRO, new SPOA lift with nuckle over steering with rear springs in the front and some nice new front and rear bumpers. However, I could stick with the lift that's on there and just do the steering.

What do you think does this sound like the correct approach?

Here's a pic after our first trip out:


Thanks,
Bill

Hey guys,
   I just picked up a 86 sammy a few weeks back and I am not preparing to start the process of making it a worthy off road vehicle. I've cleared out space in my garage to work in it but I'm not sure where to start.  So far the sammy is stock except for a home brew SPOA lift with 31" tires. I will primarily be driving it off road but I want to be able to use it as a spare car so it needs to be street legal as well. My first thought was to go with a 4.16 crawler transfer case from RRO, new SPOA lift with nuckleo ver steering with rear springs in the front and some nice new front and rear bumpers. However, I could stick with the lift that's on there and just do the steering.

What do you think does this sound like the correct approach?

Here's a pic after our first trip out:

Thanks,
Bill

Nice looking car !

I did the 4.16 recently and it makes a comfortable difference on the road, I can keep up with traffic now instead of being an obstacle, but the difference off-road is huge !! Put it in second gear and only use the throttle, no brakes, no clutch, goes like a tractor ( 215 Colway's for now )

Installation is very easy.

No comment on the knuckle over, I'm waiting for the 3" suspension raise right now ( I already installed the Calmini 3" Schackle Reversal ) and will maybe do a SPOA for the 33"s to clear off-road. Guess I'll have to do the knuckle over by then. I am going to use the 3" dropped [pitman arm and Z-link to see how it works.

Problem is there's hardly anything available overhere in the Netherlands ( just got quoted $75,- for shipping on a $ 49,- oilcoolerthermostat   )

Thanks, I have to do something to the steering. Right now it's just got a stock steering arm that's been bent, very unsafe. If nothing else I can get the Z-link arm for now.

How do you like the calmini 3" lift?
Right now I am considering the 'trailblazer' kit from RRO.
http://www.rocky-road.com/zuksus.html scrill down to find the trailblazer kit. The kit is a SPOA system, which  includes 2" lifted springs, as well as Doetsch Tech long travel shocks.

$75 is pretty steep for shipping!

Bill

You might be good with the lift you got (with addressing the steering) ...

Don't fogot to figure in lockers/gears.

That's a nice looking zuk.

Thanks, I have to do something to the steering. Right now it's just got a stock steering arm that's been bent, very unsafe. If nothing else I can get the Z-link arm for now.

How do you like the calmini 3" lift?
Right now I am considering the 'trailblazer' kit from RRO.
http://www.rocky-road.com/zuksus.html scrill down to find the trailblazer kit. The kit is a SPOA system, which  includes 2" lifted springs, as well as Doetsch Tech long travel shocks.

$75 is pretty steep for shipping!

Bill

I really like the looks and raise from the Calimini Shackle Reversal, no changes to steeringgeometry, brakes etc. Pics and text here:

http://home.planet.nl/~mverver/SAMURAIRISE.HTM

You might be good with the lift you got (with addressing the steering) ...

Don't fogot to figure in lockers/gears.

That's a nice looking zuk.

Thanks, the suspension is really stiff which my wife hates. That's the reason I was looking into the rear springs up front and the new lift.

Yeah, lockers are a must but with the new transfer case I thing I can keep the stock gears, at least for now.

Does anyone know how much of a difference the rear spring in the front actually makes? What are some other ways to soften up the suspension? OMU springs maybe?

Bill

Does anyone know how much of a difference the rear spring in the front actually makes? What are some other ways to soften up the suspension? OMU springs maybe?

Bill

OME springs are very soft and Heep Yj springs will also be very soft.  i would put OME wangler springs under it.
stu

The YJ OME springs would still be good for off roading though right?

OME springs are very soft and Heep Yj springs will also be very soft.  i would put OME wangler springs under it.
stu

The YJ OME springs would still be good for off roading though right?

ha alot more!  you will have trouble finding shocks long enough to keep up with the travel.

I drove Erics Sami with the Trail Tough YJ Kit on it and loved it .

I dont know how far we went but it had to be 1000 miles over the weekend.
It was confortable on and off road and decent flex. The only complaint I had was during on road cornering the rear end would bounce a little. (YEA, I know I was in a lifted 4x4, but I had to do my impression of consumer Reports. (Psstttt: Watch out, they will spontainously roll over on their side like a well trained dog )

I was verry impressed with the ride of the YJ Sami Kit, especially after how I heard how bad Samis ride. It was confortable throughout the entire 3 days non stop behind the wheel

Zig

I've heard nothing but good about the YJ swap.  Wanna do it to my own Sammi if I had any $$.  Might make the 33's stop rubbin.  I would agree with the long travel shocks too, looks like you're on the right track.  Two suggestions...One, don't forget the teraflex shackles with the SPOA, they're awesome.  Two, I might go with 5.38 or so ring and pinion gear instead of the crawler case.  Lil' Red Sammi and I are both geared down in the pumpkin and have stock T-case gears and it's never done us wrong.  Have fun.  Will you be making it to Gonezookin or Zuwharrie with this rig? If so, hope to see ya there!

Ring and pinion gearing would probably be cheaper. What's involved in changing out those gears? I've never done any gear work before but have decent mechanical skills. I'll look into the terraflex shackels as well, thanks.

I'm not familier with the Gonezookin or Zuwharrie events. Where and when are they held?

Bill

Ring and pinion gearing would probably be cheaper. What's involved in changing out those gears? I've never done any gear work before but have decent mechanical skills. I'll look into the terraflex shackels as well, thanks.

I'm not familier with the Gonezookin or Zuwharrie events. Where and when are they held?

Bill

Honest, I think you would get better benefit out of changing the t-case gears instead of the r&p. As far as cost goes, the smaller reduction gears. 4.16 and 5.14 are $399 to $550 respectively. Of course there are a whole lot of other gears set to choose from but lets go baseline for arguments sake.

To do the r&p you have to find USED stock gears in the 4.63 or 5.12 variety and buy install kits including  a 'diff can' to hold the spider gear pins in. So that:

USED gears: 200-500
Install kit: 130   X2
diff can 25-35 x2

Total  for R&P swap $450 - 870

vs.

T-case gear swap of $399 to $550


... and The crawl ratio, which is good for many things other than just rocks, is not as good as it would be with the t-case gears.

HTH, -Eric

I think you want both  

The diff gears to compensate for the bigger tires ...
The tcase for crawlin ...

and from a zukiworld sponser ...

Our no-hassle ready to bolt-in gear change package includes 4.62 or 5.12 Sidekick ring and pinion gears set up and installed in a Samurai front housing, a matching Sidekick rear 3rd member with drilled flanges for the Samurai drive line, and our Hybrid axle housing. Shock mounts, diff caps, SPOA perches, and Lockers are not included but can be purchased separately and installed at no extra charge.
Item #GCP-400 Price $649.00

RRO has a R&P gear set from US GEAR that says the following

"These gears are also made specifically for the Samurai so no funky install kits are necessary for a proper installation."

I'm assuming that means I and swap out my existing gears with these and don't need diff can or install kit. Is that true, has anyone used these gear sets before?

Bill